Threaded fastener

ABSTRACT

Various embodiments provide a fastener including a head, a shank connected to the head and having a tip, one or more helical thread formations extending outwardly from the shank, and wherein a bottom portion of the head includes a plurality of ribs that extend towards the tip of the shank and that are shaped to abruptly frictionally engage a surface of a first object being attached to a second object to create an immediate frictional torsional resistance of a desired force level to the tightening of the fastener. This frictional resistance is provided back to the tightening tool to inform the operator of the tightening tool that the head of the fastener has sufficiently engaged the first object and that further tightening or clockwise rotation of the fastener is unnecessary.

PRIORITY

This application is a continuation of and claims priority to and thebenefit of U.S. patent application Ser. No. 16/115,797, which was filedAug. 29, 2018, which claims priority to and the benefit of U.S.Provisional Patent Application Ser. No. 62/633,181, filed Feb. 21, 2018,and claims priority to and the benefit of U.S. Provisional PatentApplication Ser. No. 62/558,084, filed Sep. 13, 2017, the entirecontents of each of which are incorporated herein by reference.

BACKGROUND

The present disclosure relates generally to threaded fasteners that aredrivable into a substrate, and more particularly to improved one piecethreaded anchors.

Threaded fasteners such as threaded anchors are well known andcommercially used throughout the world for securing objects to a varietyof substrates. A variety of threaded fasteners can be used to secureobjects to concrete, masonry, and other cementitious substrates.Typically, such known threaded fasteners include a head, a shank, and athread formation on the shank for frictionally engaging the substrateinto which the fastener is driven. The head typically includes amechanical engaging structure for engagement by a tool that is used torotate the threaded fastener and drive the threaded fastener into thesubstrate.

Often such threaded fasteners are optimally used by pre-drilling theconcrete, masonry, or other substrate, for example with a hammer drillequipped with a masonry drill bit. Once the substrate has beenpre-drilled, and a correctly sized cavity formed therein, anappropriately sized threaded fastener may be driven or screwed into thesubstrate to secure an object thereto. One example of such a threadedfastener is described in U.S. Pat. No. 8,322,960 entitled “ThreadedConcrete Anchor” and assigned to Illinois Tool Works Inc. (which is alsothe assignee of this patent application). Such fasteners arecommercially distributed under the TAPCON® trademark, and are sometimesreferred to as TAPCON screws or anchors. TAPCON is a registeredtrademark of Illinois Tool Works Inc.

Often such threaded fasteners are driven into such a substrate using apowered tool, such as an electric or pneumatic power driving tool orimpact driver that imparts a rotational force or torque on the threadedfastener. For example, an impact driver may be fitted with anappropriate bit or socket for engaging the complimentary mechanicalengaging structure of the head of the threaded fastener, to rotate thethreaded fastener in a tightening direction such that the threads of thethreaded fastener engage the substrate. When the threaded fastener isrotated in a tightening direction, the threads of the threaded fastenergrip the inside surfaces of the substrate that define the cavity (e.g.,the surfaces that define the pre-drilled hole in the substrate), causingthe threaded fastener to be driven deeper into the substrate until thehead of the threaded fastener comes into contact with the object beingattached by the threaded fastener to the substrate (such as a bracket,flange, clip, or other mechanical device having a hole in it throughwhich the fastener passes). In the optimal situation, this contactthereby prevents the threaded fastener from being driven, rotated, ortightened further. In the optimal situation, this results in thethreaded fastener being fully tightened and the object being affixed to,secured to, or compressed into contact with the substrate.

Certain problems have arisen due to improvements in electric andpneumatic power driving tools that have caused such tools to becomecapable of delivering relatively higher levels of torque. When suchdriving tools are used to drive certain known threaded fasteners, suchas those described above, the threaded fasteners can be subjected torelatively high amounts of torque from the rotational forces imparted bythese power driving tools. For example, as the threads of the threadedfastener engage the substrate, the threaded fastener experiencesfrictional resistance forces which tend to impede further driving of thethreaded fastener into the substrate. At the same time, the powerdriving tool is imparting a rotational force or torque on the threadedfastener (via the head of the threaded fastener) in an effort tocontinue to rotate the threaded fastener in a tightening direction anddrive it into the substrate. These opposing forces impart significanttorsional stresses on the threaded fastener, placing the shank of thethreaded fastener under shearing torsional stresses.

These torsional stresses can be so great in various circumstances as tocause the threaded fastener to fail due to the opposing forces ortorques placed on the threaded fastener. Over tightening of suchthreaded fasteners during the driving process is a primary cause of suchoverstressing of the shank of the threaded fastener, and can result infailure of the threaded fastener due to such excessive torsional forces.Threaded fasteners that are subjected to over tightening often failalong the shank, including an upper portion of the shank adjacent to thehead of the threaded fastener. Other failures occur at the top of theshank, just under the head of the threaded fastener. In such failures,the head of the threaded fastener breaks off from the shank, and thusfails to hold the object to the substrate.

Accordingly, there is a need to provide threaded fasteners that solvethese problems.

SUMMARY

Various embodiments of the present disclosure provide an improvedthreaded fastener drivable into a substrate that solves the aboveproblems. For brevity, the threaded fastener of the present disclosureis sometimes referred to herein as the fastener.

In various embodiments of the present disclosure, the fastener includes:(i) a head; (ii) a shank integrally connected to the head at a first endand forming or having a tip at a second end; and (iii) one or morehelical thread formations integrally connected to and extendingoutwardly or transversely from the shank. The shank has a longitudinalaxis extending from the head to the tip.

The head includes a top portion distal from the shank, and a bottomportion adjacent to the shank. The top portion of the head defines amechanical engaging structure engageable by a suitable tool. The bottomportion of the head includes a bottom surface at least partially definedby a plurality of ribs arranged radially around a longitudinal axis ofthe head. The ribs generally extend in a direction towards the tip ofthe shank. The ribs are shaped to frictionally engage a surface of afirst object being attached to a second object such as a substrate. Theribs are configured to engage and dig into the surface of the firstobject into which the fastener is driven. The ribs are configured suchthat as the ribs approach, come into contact with, and dig into thesurface of the first object, they create a frictional torsionalresistance of a desired force level to the tightening of the fastener.This frictional resistance is provided back to the tightening tool toinform the operator of the tightening tool that the head of the fastenerhas sufficiently engaged the object and that further tightening orclockwise rotation of the fastener is unnecessary. Thus, the ribsprovide protection against over tightening of the fastener, by causingsuch frictional resistance to the tightening that can be felt by theoperator. This reduces the likelihood that the fastener will be overtightened and that the head will break off from the shank. Thus, thestructure and configuration of the threaded fastener of the presentdisclosure provide significant advantages in reducing the likelihood oftorsional failure of the fastener and undesirable failures of thefastener from over tightening.

Other objects, features, and advantages of the present disclosure willbe apparent from the following detailed disclosure, taken in conjunctionwith the accompanying sheets of drawings, wherein like referencenumerals refer to like parts.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a side perspective view of one example embodiment of athreaded fastener of the present disclosure wherein the head includesfour ribs that extend toward the tip of the shank.

FIG. 2 is an enlarged bottom view of the head of the threaded fastenerof FIG. 1 taken substantially through line 2-2 of FIG. 1 (and showing across-section of the shank of the fastener).

FIG. 3A is an enlarged fragmentary side view of the threaded fastenershowing the head of the threaded fastener of FIG. 1 and the angles ofleading faces and trailing faces of certain ribs of the head.

FIG. 3B is an enlarged side view of the leading face and the trailingface of one of the ribs of the head of the threaded fastener of FIG. 1 .

FIG. 4 is an enlarged cross-sectional view of the head of the threadedfastener of FIG. 1 taken substantially through line 4-4 of FIG. 1 , andalso showing a cross-section of the shank of the fastener.

FIG. 5 is an enlarged side fragmentary view of the threaded fastener ofFIG. 1 being inserted through an object and into a substrate to attachthe object to the substrate, and showing the head of the threadedfastener just as the ribs of the head engage the outer surface of theobject.

FIG. 6 is an enlarged side fragmentary view of the threaded fastener ofFIG. 1 being inserted through an object and into a substrate to attachthe object to the substrate, and showing the head of the threadedfastener after the ribs of the head have engaged and dug into or enteredinto the object.

FIG. 7 is an enlarged side fragmentary view of the threaded fastener ofFIG. 1 being inserted through an object and into a substrate to attachthe object to the substrate, and showing the head of the threadedfastener in an offset position just as one of the ribs of the headengages the outer surface of the object.

FIG. 8 is an enlarged bottom view of the head of an alternative exampleembodiment of a threaded fastener of the present disclosure thatincludes six ribs.

FIGS. 9 and 10 are charts that provide certain dimensions for examplefasteners made in accordance with the present disclosure.

FIG. 11A is a side perspective view of another example embodiment of athreaded fastener of the present disclosure wherein the head includesfour multi-part ribs that extend toward the tip of the shank.

FIG. 11B is a side view of the threaded fastener of FIG. 11 .

FIG. 12 is an enlarged bottom view of the head of the threaded fastenerof FIG. 11A, and taken substantially through line 12-12 of FIG. 11 toshow a cross-section of the shank of the threaded fastener.

FIG. 13A is an enlarged fragmentary side view of the threaded fastenerof FIG. 11A showing the head and the angles of multi-part leading facesand multi-part trailing faces of certain ribs of the head.

FIG. 13B is an enlarged top view of the head of the threaded fastener ofFIG. 11A.

FIG. 14 is an enlarged cross-sectional view of the head of the threadedfastener of FIG. 11A taken substantially through line 14-14 of FIG. 13A,and also showing a fragmentary cross-section of the shank of thethreaded fastener.

FIG. 15 is a fragmentary side perspective view of a known threadedfastener, and illustrating the stress patterns on the shank and the headof this known threaded fastener determined by a computer simulatedstress test conducted on this known threaded fastener.

FIG. 16 is a fragmentary side perspective view of the threaded fastenerof FIG. 1 , and illustrating the stress patterns on the shank and thehead of this threaded fastener determined by a computer simulated stresstest conducted on this new threaded fastener.

DETAILED DESCRIPTION

Referring now to the Figures, a threaded fastener 100 of one exampleembodiment of the present disclosure is generally shown in FIGS. 1, 2,3A, 3B, 4, 5, 6, and 7 . The example fastener 100 is configured for usein fastening such as for anchoring objects to substrates, and inparticular for securing or anchoring an object or portion of an objectto a concrete, masonry, or another such substrate. The example fastener100 generally includes a head 110, a shank 180 integrally connected tothe head 110, and a thread formation 190 integrally connected to andextending outwardly from the shank 180.

In this illustrated example embodiment of this present disclosure, theshank 180 has a first end 182, a second end 184, a length L1, and isintegrally connected to the head 110 at the first end 182 of the shank180. The first end 182 of the shank 180 in this illustrated embodimentincludes a chamfered portion. The second end 184 of the shank 180 (thatis opposite the first end 182 of the shank 180) forms a tip 186. In thisexample embodiment, the tip 186 is pointed to aid in penetrating thesubstrate in which the fastener 100 is driven. The shank 180 has acentral longitudinal axis A1 extending along the length L1 of the shank180, generally from the head 110 to the tip 186 of the shank 180. Theshank 180 including the chamfered portion at the first end 182 isconfigured to fit through the hole in the object 10 as generally shownin FIGS. 5, 6, and 7 . It should be appreciated that the configurationof the shank can vary in accordance with the present disclosure.

In this illustrated example embodiment of this present disclosure, thethread formation 190 includes: (a) a first or primary helical threadformation 192 along or extending outwardly or transversely from aportion of the shank 180; and (b) a second or secondary helical threadformation 194 along or extending outwardly or transversely from aportion of the shank 180. It should be appreciated that the formationand configuration of the threads of the respective first and secondhelical thread formations 192 and 194 may take on a variety of differentforms in accordance with the present disclosure. In one embodiment, thefirst and second helical thread formations 192 and 194 are formed in amanner to maximize grip strength of the fastener 100 for use inconcrete, masonry, and other cementitious substrates. One example of thefirst and second helical thread formations 192 and 194 that may beappropriate for certain applications of the present disclosure aredescribed in U.S. Pat. No. 8,322,960. It should also be appreciated thatthe quantity of the threads, and specifically the quantity of the firstand second helical thread formations may vary in accordance with thepresent disclosure.

In this illustrated example embodiment of this present disclosure, thehead 110 of the fastener 100 includes a top portion 120 distal to andspaced from the shank 180, and a bottom portion 130 proximate to andintegrally connected to the shank 180. The top portion 120 of the head110 defines a mechanical engaging structure 122 that is engageable by anappropriate tool for driving the fastener 100. In this illustratedexample embodiment of the present disclosure, the mechanical engagingstructure 122 includes a hexagonal shaped bolt head that is engageableby an appropriate tool, such as a socket wrench or impact driver. Inother embodiments of the present disclosure, other mechanical engagingstructures may be utilized, such as a straight slot (engageable by aflathead screwdriver), a cross-shaped slot (engageable by a Phillipshead screwdriver), or a hexagonal shaped cavity (engageable by an Allenwrench). Any suitable mechanical engaging structures rotatable ordrivable by one or more suitable tools may be employed as the engagingstructure 122 in accordance with the present disclosure. The head 110has a central longitudinal axis A2 extending from the top portion to thebottom portion, and which is aligned with or extends along the same axisas the longitudinal axis A1 of the shank 180.

The bottom portion 130 of the head 110 includes a bottom surface 132formed by a plurality of extrusions or ribs, and specifically in thisillustrated example embodiment four extrusions or ribs 140 a, 140 b, 140c, and 140 d extending toward the tip 186 of the shank 180. Theextrusions or ribs 140 a, 140 b, 140 c, and 140 d are arranged radiallyaround the central longitudinal axis A2 of the head 110. The bottomsurface 132 of the head 110 in this illustrated embodiment is formed bythe extrusions or ribs 140 a, 140 b, 140 c, and 140 d and generallyfaces towards the tip 186 of the shank 180. It should be appreciatedthat in this illustrated example embodiment, each of the extrusions orribs 140 a, 140 b, 140 c, and 140 d thus provides a part of the bottomsurface of the head 110. In other embodiments which are not illustrated,the extrusions or ribs only provide part of the bottom surface of thehead of the fastener.

This illustrated example embodiment includes four identically sized andshaped ribs 140 a, 140 b, 140 c, and 140 d. In this illustrated exampleembodiment, each identically configured rib includes a leading face anda trailing face that meet or intersect at an edge of that rib. It shouldbe appreciated that the ribs do not need to be identical in accordancewith the present disclosure.

More specifically, in this illustrated example embodiment: (a) rib 140 aincludes a leading face 150 a and a trailing face 160 a that meet at atransversely (or inwardly/outwardly) extending leading edge 170 a of rib140 a; (b) rib 140 b includes a leading face 150 b and a trailing face160 b that meet at a transversely (or inwardly/outwardly) extendingleading edge 170 b of rib 140 b; (c) rib 140 c includes a leading face150 c and a trailing face 160 c that meet at a transversely (orinwardly/outwardly) extending leading edge 170 c of rib 140 c; and (d)rib 140 d includes a leading face 150 d and a trailing face 160 d thatmeet at a transversely (or inwardly/outwardly) extending leading edge170 d of rib 140 d.

In this illustrated example embodiment: (a) rib 140 a and specificallythe leading edge 170 a of rib 140 a includes an apex 180 a at theoutermost end point of the leading edge 170 a; (b) rib 140 b andspecifically the leading edge 170 b of rib 140 b includes an apex 180 bat the outermost end point of the leading edge 170 b; (c) rib 140 c andspecifically the leading edge 170 c of rib 140 c includes an apex 180 cat the outermost end point of the leading edge 170 c; and (d) rib 140 dand specifically the leading edge 170 d of rib 140 d includes an apex180 d at the outermost end point of the leading edge 170 d.

In this illustrated example embodiment: (a) the trailing face 160 a ofrib 140 a extends toward and all the way to the leading face 150 b ofrib 140 b; (b) the trailing face 160 b of rib 140 b extends toward andall the way to the leading face 150 c of rib 140 c; (c) the trailingface 160 c of rib 140 c extends toward and all the way to the leadingface 150 d of rib 140 d; and (d) the trailing face 160 d of rib 140 dextends toward and all the way to the leading face 150 a of rib 140 a.In this manner, the ribs 140 a, 140 b, 140 c, and 140 d define theentire bottom surface of the bottom portion 130 of the head 110.

It should be appreciated that in other embodiments, the angles of theribs and particularly the angles of the leading and trailing faces canbe slightly varied such that the respective trailing face of one or moreof the ribs does not extend all the way to the adjacent rib or theadjacent leading face of that adjacent rib (i.e., it stops short of thatadjacent leading face). In such instances, a planer surface on orparallel to plane 134 can be provided between such adjacent ribs.

In this illustrated example embodiment, as best shown in FIGS. 3A, 4, 5,6, and 7 , each of the ribs 140 a, 140 b, 140 c, and 140 d is inwardlytapered or angled from the outer surface of the head 110 or of thebottom portion 130 of the head 110 toward the central longitudinal axisA2 of the head 110. The taper in this illustrated example embodimentstops at or adjacent to the shaft 180 as generally shown in FIG. 2 .

For example, as shown in FIG. 4 , the leading face 150 b of rib 140 b isinwardly tapered or angled from the outer surface of the head 110 (or ofthe bottom portion 130 of the head 110) toward the central longitudinalaxis A2 of the head 110. Likewise, the trailing face 160 b of rib 140 bis inwardly tapered or angled from the outer surface of the head 110 (orof the bottom portion 130 of the head 110) toward the centrallongitudinal axis A2 of the head 110. Thus, the leading edge 170 b isalso inwardly tapered from the apex 180 b at the outermost end point ofthe leading edge 170 b toward the central longitudinal axis A2 of thehead 110.

It should thus be appreciated that in this illustrated exampleembodiment: (a) the leading face 150 a is substantially triangular; (b)the leading face 150 b is substantially triangular; (c) the leading face150 c is substantially triangular; and (d) the leading face 150 d issubstantially triangular. It should similarly be appreciated that theleading face of each rib (such as rib 140 b) thus has a larger surfacearea toward the apex (such as apex 180 b) of the head 100 than towardthe central longitudinal axis A2 of the head 110. In this illustratedexample embodiment, the angle of the taper or the angle from the apextoward the central longitudinal axis A2 of the head is approximately 75degrees. It should be appreciated that each leading face does not needto be triangular or substantially triangular in accordance with thepresent disclosure. For example, in other embodiments, the leading facesare more trapezoid such that the edges 170 a, 170 b, 170 c, and 1070 ddo not converge to plane 134, but rather extend to the shaft 180. Insuch embodiments, the angle of the taper or the angle from the apextoward the central longitudinal axis A2 of the head is approximately 83or 84 degrees and can be in a range of approximately 60 to 85 degrees.

In this illustrated embodiment, since all of the ribs 140 a, 140 b, 140c, and 140 d are configured and equally sized and spaced around the head110, for brevity, ribs 140 a and 140 b are primarily or mainly discussedin additional detail below.

As best shown in FIGS. 3A and 3B, the leading face 150 a of rib 140 aforms an angle A with respect to the trailing face 160 d of the radiallyadjacent rib 140 d. In this illustrated embodiment, angle A isapproximately 102.5 degrees. In various other example embodiments of thepresent disclosure, angle A can range from approximately 92 degrees toapproximately 103 degrees; however, it should be appreciated that thisrange of angles is not meant to limit the present disclosure.

As best shown in FIGS. 3A and 3B, the leading face 150 a of rib 140 aforms an angle B with respect to a plane 134 extending though the bottomportion 130 of the head 110 and generally parallel with the uppersurface of the head 110. In this illustrated embodiment, angle B isapproximately 105 degrees. In various other example embodiments of thepresent disclosure, angle B can range from approximately 90 degrees toapproximately 120 degrees; however, it should be appreciated that thisrange of angles is not meant to limit the present disclosure.

As best shown in FIGS. 3A and 3B, the trailing face 160 a of rib 140 aforms an angle C with respect to the leading face 150 a of the rib 140a. In this illustrated embodiment, angle C is approximately 102.5degrees. In various other example embodiments of the present disclosure,angle C can range from approximately 92 degrees to approximately 103degrees; however, it should be appreciated that this range of angles isnot meant to limit the present disclosure.

As best shown in FIGS. 3A and 3B, the trailing face 160 a of rib 140 aforms an angle D with respect to a plane 136 extending though the bottomportion 130 of the head 110 and generally parallel with the top or uppersurface of the head 110. In this illustrated embodiment, angle D isapproximately 2.5 degrees. In various other example embodiments of thepresent disclosure, angle D can range from approximately 2 degrees toapproximately 12.5 degrees; however, it should be appreciated that thisrange of angles is not meant to limit the present disclosure.

In this illustrated example embodiment, angle C is equal to angle A. Inthis illustrated example embodiment, angle D is substantially less thanangles A and B such that the leading face 150 a is at a substantiallysharper angle with respect to an object such as object 10 (see FIGS. 5,6, and 7 ), with which the head 110 of the fastener 100 is going toengage, and the trailing face 160 a is at a much shallower angle withrespect to the object such as object 10. In other words, in thisillustrated embodiment, the leading face 150 a of the rib 140 a(provides a relatively shallow angled face) and the trailing face 160 aof rib 140 a (provides a relatively steep angled face). Thisconfiguration enables the shallow angled rib 140 a to abruptly dig inthe object as the ribs engage the outer surface of the objects therebyimmediately transferring relatively significant force to or through thehead 110 and back to the operator of the driving tool as furtherdescribed below.

It should be appreciated that the angles of the leading face andtrailing face of each rib can vary with the size of the fastener inaccordance with the present disclosure.

It should be appreciated that the fastener 100 is a right-handedthreaded fastener, such that when it is rotated in a clockwise fashionabout axis A2 (when looking at the top portion 120 of the head 110), thefastener 100 is tightened or driven, and when rotated in acounter-clockwise fashion about axis A2 (when looking at the top portion120 of the head 110), the fastener 100 is loosened or backed out.

In other example embodiments of the present disclosure, the fastener isleft-hand threaded such that the fastener is configured to be tightenedor driven in a counter-clockwise direction and loosened or backed out ina clockwise direction. In such embodiments, the directions of the ribsand particularly the leading faces and trailing faces are reversed.

In use or operation, when the head 110 of the fastener 100 is tightened,driven, or rotated in a clockwise direction, the threads 192 and 194 ofthe fastener 100 can grip the substrate 20 to drive the shank 180 of thefastener 100 through the object 10 and into the substrate 20. Duringthis driving process, the ribs 140 a, 140 b, 140 c, and 140 d areconfigured to eventually come into contact with the outer surface of theobject 10 as generally shown in FIG. 5 (which shows the fastener 100positioned in a perpendicular orientation to the object 10). Likewise,when the head 110 of the fastener 100 is loosened or backed out, in acounter-clockwise direction, the threads 192 and 194 of the fastener 100release their grip on substrate 20, and the fastener 100 is backed outof the substrate 20 and the object 10, causing the ribs 140 a, 140 b,140 c, and 140 d to come out of contact with the object 10.

As shown in FIG. 5 , as the fastener 100 is tightened (in the clockwisedirection), the apexes 180 a, 180 b, 180 c, and 180 d of the respectiveleading edges 170 a, 170 b, 170 c, and 170 d of the respective ribs 140a, 140 b, 140 c, and 140 d first come into contact with the outersurface of the object 10 as the fastener 100 is tightened or rotated inthe clockwise direction. The leading faces 150 a, 150 b, 150 c, and 150d of the ribs 140 a, 140 b, 140 c, and 140 d then come into contact withthe outer surface of the object 10 as the fastener 100 is furthertightened or rotated in the clockwise direction. The ribs at this pointhave abruptly come into contact with the outer surface of the object 10.

As shown in FIG. 6 , after the apexes 170 a, 170 b, 170 c, and 170 dhave contacted the object 10 during the tightening process, and thefastener 100 continues to be rotated in a clockwise direction, therelatively sharp angles of the leading faces 150 a, 150 b, 150 c, and150 d of the ribs 140 a, 140 b, 140 c, and 140 d further to dig into orbite into the object 10 below the outer surface of the object 10. Thiscreates a relatively substantial frictional torsional resistance (of adesired force level) to the tightening of the fastener 100. Thisfrictional resistance is immediately provided back to the operatorthrough the tightening tool (such as an impact driver) to inform theoperator of the tightening tool (such as the operator of the impactdriver) that the head 110 has sufficiently engaged the object 10 andthat further tightening or clockwise rotation of the fastener 100 isunnecessary. Thus, the ribs 140 a, 140 b, 140 c, and 140 d provideprotection against over tightening of the fastener 100 by causing suchrelatively substantial frictional resistance to the tightening that canbe immediately felt by the operator of the tightening tool. This reducesthe likelihood that the fastener 100 will be over tightened and that thefastener with fail. The structure and configuration of the threadedfastener of the present disclosure thus provide significant advantagesin reducing the likelihood of torsional failure of the fastener and thusundesirable failures of the fastener from over tightening.

As mentioned above, FIG. 5 illustrates the relative position of thefastener 100, the head 110 of the fastener 100, and the ribs 104 a, 140b, and 140 d of the head 110 of the fastener 100 when the fastener 100is perpendicular to the object 10. However, often times, an operatorwill not position the fastener 100 perpendicular to the object 10. Thus,FIG. 7 illustrates the relative position of the fastener 100, the head110 of the fastener 100, and the ribs 104 a, 140 b, and 140 d of thehead 110 of the fastener 100 when the fastener 100 is not perpendicularto the object 10. The present disclosure accounts for such situations asshown in FIG. 7 , in that one or more of the apexes of the ribs such asapex 180 d first abruptly engages the outer surface of the object 10 andas the fastener 100 continues to rotate, the leading face 150 d of rib140 d of the fastener 100 digs or bites into the object 10 and providesimmediate feedback to the operator of the tightening tool.

It should also be appreciated that when the fastener 100 is loosened orbacked out in the counter-clockwise direction, the shallower angle ofthe trailing edges 160 a, 160 b, 160 c, and 160 d of the ribs 140 a, 140b, 140 c, and 140 d lessen the frictional torsional resistance betweenthe head 110 and the object 10 to enable the fastener 100 to be removedmore easily.

It should further be appreciated that for such fasteners, having six orless (and particularly four) such configured ribs provides an optimaldesired combination of angles for the leading and trailing surfaces ofthe ribs, and that such relatively fewer ribs provide an unexpectedresult of optimal performance (as opposed to having more than six ribsextending toward the shaft testing of which showed much poorer results).

It should be appreciated that for example fastener 100, only having fourribs 140 a, 140 b, 140 c, and 140 d provides a highly desired andeffective combination of angles for the leading and trailing faces ofthe ribs that provide an unexpected result of optimal performance.

Testing has revealed that six or less, and specifically four such ribsarranged in the manner described above are extremely effective attransferring torque away from the shank of the fastener and back throughthe tool to the operator. This is partly because at the point when theribs first engage the object, they do not completely dig in the object,but need to further rotate a certain number of degrees (such as 54degrees for a ¼ inch fastener with a 0.02 inch maximum height of thetapered leading face; 108 degrees for a ¼ inch fastener with a 0.04 inchmaximum height of the tapered leading face; 57.6 degrees for a 3/16 inchfastener with a 0.02 inch maximum height of the tapered leading face;and 115.2 degrees for a 3/16 inch fastener with a 0.04 inch maximumheight of the tapered leading face) to fully engage the full rib height.This provides the optimal feedback through the head and back to thefastener driving tool.

In various embodiments, the fastener of the present disclosure andspecifically the ribs are made using a cold forming manufacturingprocess and specifically using a tooling die formed from metal or metalalloys that are suitable to withstand the forces applied. The inwardtapering of the ribs reduces the amount of material that must be used toform each rib, and also reduces the stress on the tooling die andimproves die life.

Referring now to FIG. 8 , a threaded fastener 200 of another exampleembodiment of the present disclosure is generally shown. The fastener200 is also configured for use in fastening such as anchoring an objectto a substrate, and in particular for securing or anchoring an object toa concrete, masonry, or another substrate. The example fastener 200includes a head 210, a shank 280 (partially shown), and a threadformation (not shown) extending outwardly from the shank 280.

The bottom portion 230 of the head 210 includes a bottom surface 232formed by a plurality of extrusions or ribs extending toward the tip(not shown) of the shank 280. The extrusions or ribs are arrangedradially around a longitudinal axis (not shown) of the head 210.

This illustrated example embodiment includes six identically sized andshaped ribs 240 a, 240 b, 240 c, 240 d, 240 e, and 240 f. In thisillustrated example embodiment, each rib includes a leading face and atrailing face that meet at a leading edge of that rib. Morespecifically, in this illustrated example embodiment: (a) rib 240 aincludes a leading face and a trailing face that meet at a leading edgeof rib 240 a; (b) rib 240 b includes a leading face and a trailing facethat meet at a leading edge of rib 240 b; (c) rib 240 c includes aleading face and a trailing face that meet at a leading edge of rib 240c; (d) rib 240 d includes a leading face and a trailing face that meetat a leading edge of rib 240 d; (e) rib 240 e includes a leading faceand a trailing face that meet at a leading edge of rib 240 e; and (f)rib 240 f includes a leading face and a trailing face that meet at aleading edge of rib 240 f. In this illustrated example embodiment, eachof the ribs 240 a, 240 b, 240 c, 240 d, 240 e, and 240 f are alsoinwardly tapered or angled from the outer surface of the head 210 towardan inner area or the central axis of the head 210.

In this illustrated example embodiment: (a) the trailing face of rib 240a extends toward and all the way to the leading face of rib 240 b; (b)the trailing face of rib 240 b extends toward and all the way to theleading face of rib 240 c; (c) the trailing face of rib 240 c extendstoward and all the way to the leading face of rib 240 d; (d) thetrailing face of rib 240 d extends toward and all the way to the leadingface of rib 240 e; (f) the trailing face of rib 240 e extends toward andall the way to the leading face of rib 240 f; and (g) the trailing faceof rib 240 f extends toward and all the way to the leading face of rib240 a. In this manner, the ribs 240 a, 240 b, 240 c, 240 d, 240 e, and240 f define the entire bottom surface of the bottom portion of the head210.

In this illustrated example embodiment, each of the ribs 240 a, 240 b,240 c, 240 d, 240 e, and 240 f is inwardly tapered or angled from theouter surface of the head 210 or of the bottom portion 230 of the head210 toward the central longitudinal axis of the head 210.

During this driving process, the ribs 240 a, 240 b, 240 c, 240 d, 240 e,and 240 f are configured to eventually come into contact with the outersurface of the object. As the fastener 200 is tightened (in theclockwise direction), the leading edges and leading faces of the ribs240 a, 240 b, 240 c, 240 d, 240 e, and 240 f come into contact with theouter surface of the object as the fastener 200 is tightened or rotatedin the clockwise direction. After the fastener 200 continues to berotated in a clockwise direction, the relatively sharp angles of theleading faces begin to dig into or bite into the object below the outersurface of the object. This creates a desired amount of frictionaltorsional resistance of a desired force level to the tightening of thefastener 200. This frictional resistance is provided back to thetightening tool (such as an impact driver) to inform the operator of thetightening tool (such as the operator of the impact driver) that thehead 210 had sufficiently engaged an object and that further tighteningor clockwise rotation of the fastener is unnecessary. Thus, the ribs 240a, 240 b, 240 c, 240 d, 240 e, and 240 f provide protection against overtightening of the fastener 200, by causing such frictional resistance tothe tightening that can be felt by the operator. This reduces thelikelihood that the fastener 200 will be over tightened. The structureand configuration of the threaded fastener of the present disclosureprovide significant advantages in reducing the likelihood of torsionalfailure of the fastener and undesirable failures of the fastener fromover tightening.

It should also be appreciated that the fastener 200 of this illustratedexample embodiment includes six ribs 240 a, 240 b, 240 c, 240 d, 240 e,and 240 f. The combination of these six ribs and the specific leadingedges of these ribs provide an optimal combination for providing adesired amount of frictional torsional resistance back to the tighteningtool.

It should thus be appreciated from these examples that for many suitablysized threaded anchors of 3/16 inch and ¼ inch sizes, that four to sixribs will provide the ideal feedback for the operator of a tighteningtool.

It should be appreciated that in other alternative embodiments of thepresent disclosure, each of the ribs are not identical as shown in theabove described embodiments for fastener 100 and fastener 200.

It should be appreciated that the fastener 100 and fastener 200 are madefrom carbon steel, but can be made from other suitable materials.

The two charts shown in FIGS. 9 and 10 further provide the dimensionsfor example fasteners made in accordance with the present disclosure.These charts reference the angles A, B, and C from FIGS. 3 and 4 .

FIG. 15 shows the results of a stress test (and specifically a computergenerated finite element analysis (FEA) simulation) conducted on a knownthreaded fastener, and specifically the stress patterns on the shank andthe head of this known threaded fastener. This known fastener 10generally includes a head 11, a shank 18 integrally connected to thehead 11, and a thread formation (not shown) integrally connected to andextending outwardly from the shank 18. The shank 18 has a first end 18 aintegrally connected to the head 11. The head 11 of the fastener 10includes a top portion 12 distal to and spaced from the shank 18, and abottom portion 13 proximate to and integrally connected to the shank 18.

The stress test (and specifically the computer generated FEA simulation)conducted on this known threaded fastener 10 reveals that during therotational driving process, when the bottom portion 13 comes intocontact with the outer surface of an object (not shown), the higheststress levels are placed on: (1) the first end 18 a of the shank 18adjacent to the bottom portion 13 of the head 11 (as indicated bypattern H1); (2) an area of the bottom portion 13 of the head 11adjacent to the first end 18 a of the shank 18 (as indicated by patternH2); and (3) an outer area of the bottom portion 13 of the head 11adjacent to the outer edge of the bottom portion 13 (as indicated bypattern H3).

The stress test (and specifically the computer generated FEA simulation)conducted on this known threaded fastener further reveals that thatduring the rotational driving process, when the bottom portion 13 comesinto contact with the outer surface of an object (not shown), relativelylower stress levels are placed on: (1) an area of the shank adjacent tothe first end 18 a of the shank 18 (as indicated by pattern M1); (2) anarea of the bottom portion 13 of the head 11 (as indicated by patternM2); and (3) an area of the top portion 12 of the head 11 adjacent tothe bottom portion 13 (as indicated by pattern M3).

The stress test (and specifically the computer generated FEA simulation)conducted on this known threaded fastener further reveals that thatduring the rotational driving process, when the bottom portion 13 comesinto contact with the outer surface of an object (not shown), evenrelatively lower stress levels are placed on: (1) an area of the shankfurther from to the first end 18 a of the shank 18 (as indicated bypattern L1); (3) an area of the top portion 12 of the head 11 spacedfrom the bottom portion 13 (as indicated by pattern L3).

Thus, the stress test (and specifically the computer generated FEAsimulation) conducted on this known threaded fastener reveals that thehighest stress levels are placed on the first end 18 a of the shank 18,and that area is the most likely area to suffer a rupture or breakage.

FIG. 16 shows the results of same stress test (and specifically thecomputer generated FEA simulation) conducted on a sample threadedfastener with a head and shank made generally in accordance with theexample embodiment of FIGS. 1 to 7 (described above), and specificallythe stress patterns on the shank and the head of this sample threadedfastener. This fastener 2100 generally includes a head 2110, a shank2180 integrally connected to the head 2110, and a thread formation (notshown) integrally connected to and extending outwardly from the shank2180. The shank 2180 has a first end that includes a chamfered portion2182 integrally connected to the head 2110. The head 2110 of thefastener 2100 includes a top portion 1120 distal to and spaced from theshank 2180, and a bottom portion 2130 proximate to and integrallyconnected to the chamfered portion 2182 of the shank 2180. The bottomportion 2130 of the head 2110 includes a bottom surface 2132 formed byfour extrusions or ribs 2140 a, 2140 b, 2140 c, and 2140 d extendingtoward the tip (not shown) of the shank 2180. The extrusions or ribs2140 a, 2140 b, 2140 c, and 2140 d are arranged radially around thecentral longitudinal axis of the head 2110 and are configured asdescribed above with respect to FIGS. 1 to 7 .

The stress test (and specifically the computer generated FEA simulation)conducted on this sample threaded fastener reveals that that during therotational driving process, when the bottom portion 2130 comes intocontact with the outer surface of an object (not shown), the higheststress levels are placed on: (1) the bottom portion 2130 of the head2110 including the extrusions or ribs 2140 a, 2140 b, 2140 c, and 2140 d(as indicated by pattern H1); and (2) a small area of the top of thechamfered portion 2182 of the shank 2180 adjacent to the bottom portion2130 of the head 2110 (as indicated by pattern H2).

The stress test (and specifically the computer generated FEA simulation)conducted on this sample threaded fastener further reveals that thatduring the rotational driving process, when the bottom portion 2130comes into contact with the outer surface of an object (not shown),relatively lower stress levels are placed on: (1) most of the chamferedportion 2182 of the shank 2180 (as indicated by pattern M1); (2) an areaof the shank 2180 adjacent to the chamfered portion 2182 of the shank2180 (as indicated by pattern M2); and (3) an area of the top portion2120 of the head 2110 adjacent to the bottom portion 2130 (as indicatedby pattern M3).

The stress test (and specifically the computer generated FEA simulation)conducted on this sample threaded fastener further reveals that thatduring the rotational driving process, when the bottom portion 2130comes into contact with the outer surface of an object (not shown), evenrelatively lower stress levels are placed on: (1) an area of the shankfurther from the chamfered portion 2182 of the shank 2180 (as indicatedby pattern L1); and (2) an area of the top portion 2120 of the head 2110spaced from the bottom portion 2130 of the head 2110 (as indicated bypattern L3).

Thus, the stress test (and specifically the computer generated FEAsimulation) reveals that the most stress is placed on the bottom portion2130 of the head 2110 including the extrusions or ribs 2140 a, 2140 b,2140 c, and 2140 d (as indicated by pattern H1), and thus that the shank2180 is substantially less likely to suffer a rupture or breakage.

Referring now to FIGS. 11A, 11B, 12, 13A, 13B, and 14 , a threadedfastener 1100 of another example embodiment of the present disclosure isgenerally shown. The fastener 1100 is also configured for use infastening such as anchoring an object to a substrate, and in particularfor securing or anchoring an object to a concrete, masonry, or anothersubstrate. The example fastener 1100 includes a head 1110, a shank 1180,and a thread formation 1190 extending outwardly from the shank 1180.

In this illustrated example embodiment, the thread formation 1190includes two different size outwardly extending helical threads 1192 and1194. More specifically, in this illustrated example embodiment of thispresent disclosure, the thread formation 1190 includes: (a) a first orprimary helical thread formation 1192 along or extending outwardly ortransversely from a portion of the shank 1180; and (b) a second orsecondary helical thread formation 1194 along or extending outwardly ortransversely from a portion of the shank 1180. It should be appreciatedthat the formation and configuration of the threads of the respectivefirst and second helical thread formations 1192 and 1194 may take on avariety of different forms in accordance with the present disclosure. Inone embodiment, the first and second helical thread formations 1192 and1194 are formed in a manner to maximize grip strength of the fastener1100 for use in concrete, masonry, and other cementitious substrates.One example of the first and second helical thread formations 1192 and1194 that may be appropriate for certain applications of the presentdisclosure are described in U.S. Pat. No. 8,322,960. It should also beappreciated that the quantity of the threads, and specifically thequantity of the first and second helical thread formations may varietyin accordance with the present disclosure.

In this illustrated example embodiment, the bottom portion 1130 of thehead 1110 includes a bottom surface 1132 formed by a plurality ofmulti-part extrusions or ribs 1140 a, 1140 b, 1140 c, and 1140 dextending toward the tip 1181 of the shank 1280. The multi-partextrusions or ribs 1140 a, 1140 b, 1140 c, and 1140 d are arrangedradially around a longitudinal axis A1 of the head 1110. In thisillustrated example embodiment, the four multi-part ribs 1140 a, 1140 b,1140 c, and 1140 d are identically sized and shaped. It should beappreciated that in other embodiments, these multi-part ribs do not needto be identically sized and shaped.

In this illustrated example embodiment, each multi-part rib includes amulti-part leading face and a multi-part trailing face that meet at aleading edge of that multi-part rib. More specifically, in thisillustrated example embodiment: (a) multi-part rib 1140 a includes amulti-part leading face 1150 a and a multi-part trailing face 1160 athat meet at a multi-part leading edge 1170 a of multi-part rib 1140 a;(b) multi-part rib 1140 b includes a multi-part leading face 1150 b anda multi-part trailing face 1160 b that meet at a multi-part leading edge1170 b of multi-part rib 1140 b; (c) multi-part rib 1140 c includes amulti-part leading face 1150 c and a multi-part trailing face 1160 cthat meet at a multi-part leading edge 1170 c of multi-part rib 1140 c;and (d) multi-part rib 1140 d includes a multi-part leading face 1150 dand a multi-part trailing face 1160 d that meet at a multi-part leadingedge 1170 d of multi-part rib 1140 d.

In this illustrated example embodiment: (a) the multi-part leading face1150 a includes a first face and a second face disposed at an obtuseangle from the first face; (b) the multi-part leading face 1150 bincludes a first face and a second face disposed at an obtuse angle; (c)the multi-part leading face 1150 c includes a first face and a secondface disposed at an obtuse angle; and (d) the multi-part leading face1150 d includes a first face and a second face disposed at an obtuseangle. It should be appreciated that these angles may vary in accordancewith the present disclosure.

In this illustrated example embodiment: (a) the multi-part trailing face1160 a includes a first surface and a second surface that generallyextends at an obtuse angle from the first surface; (b) the multi-parttrailing face 1160 b includes a first surface and a second surface thatgenerally extends at an obtuse angle from the first surface; (c) themulti-part trailing face 1160 c includes a first surface and a secondsurface that generally extends at an obtuse angle from the firstsurface; and (d) the multi-part trailing face 1160 d includes a firstsurface and a second surface that generally extends at an obtuse anglefrom the first surface.

In this illustrated example embodiment: (a) the multi-part leading edgeof rib 1170 a includes a first edge and a second edge that generallyextends at an obtuse angle from the first edge; (b) the multi-partleading edge of rib 1170 b includes a first edge and a second edge thatgenerally extends at an obtuse angle from the first edge; (c) themulti-part leading edge of rib 1170 c includes a first edge and a secondedge that generally extends at an obtuse angle from the first edge; and(d) the multi-part leading edge 1170 d includes a first edge and asecond edge that generally extends at an obtuse angle from the firstedge.

In this illustrated example embodiment: (a) the trailing face ofmulti-part rib 1140 a extends toward and all the way to the leading faceof multi-part rib 1140 b; (b) the trailing face of multi-part rib 1140 bextends toward and all the way to the leading face of multi-part rib1140 c; (c) the trailing face of multi-part rib 1140 c extends towardand all the way to the leading face of multi-part rib 1140 d; and (d)the trailing face of multi-part rib 1140 d extends toward and all theway to the leading face of multi-part rib 1140 a. In this manner, themulti-part ribs 1140 a, 1140 b, 1140 c, and 1140 d define the entirebottom surface of the bottom portion of the head 1210.

In this illustrated example embodiment, each of the multi-part ribs 1140a, 1140 b, 1140 c, and 1140 d are also inwardly tapered or angled fromthe outer surface of the head 1210 toward an inner area or the centralaxis A1 of the head 1110.

In this illustrated example embodiment, the top portion of the head isnot circular; rather, it is notched. In other example embodiments, thetop portion of the head is circular.

In this illustrated example embodiment, the top portion of the head hasa star shaped mechanical engaging structure as shown in FIG. 13B. Itshould be appreciated that it can have any suitable structure.

During this driving process, the multi-part ribs 1140 a, 1140 b, 1140 c,and 1140 d are configured to eventually come into contact with the outersurface of the object. As the fastener 1100 is tightened (in theclockwise direction), the leading edges and leading faces of themulti-part ribs 1140 a, 1140 b, 1140 c, and 1140 d come into contactwith the outer surface of the object as the fastener 1100 is tightenedor rotated in the clockwise direction. After the fastener 1100 continuesto be rotated in a clockwise direction, the relatively sharp angles ofthe multi-part leading faces begin to dig into or bite into the objectbelow the outer surface of the object. This creates a desired amount offrictional torsional resistance of a desired force level to thetightening of the fastener 1100. This frictional resistance is providedback to the tightening tool (such as an impact driver) to inform theoperator of the tightening tool (such as the operator of the impactdriver) that the head 1110 had sufficiently engaged an object and thatfurther tightening or clockwise rotation of the fastener is unnecessary.Thus, the multi-part ribs 1140 a, 1140 b, 1140 c, and 1140 d provideprotection against over tightening of the fastener 1200, by causing suchfrictional resistance to the tightening that can be felt by theoperator. This reduces the likelihood that the fastener 1100 will beover tightened. The structure and configuration of the threaded fastenerof the present disclosure provide significant advantages in reducing thelikelihood of torsional failure of the fastener and undesirable failuresof the fastener from over tightening.

It should also be appreciated that the fastener 1100 of this illustratedexample embodiment includes four ribs 1140 a, 1140 b, 1140 c, and 1140d. The combination of these four multi-part ribs and the specificleading edges of these multi-part ribs provide an optimal combinationfor providing a desired amount of frictional torsional resistance backto the tightening tool.

It should be appreciated from the above, that various embodiments of thepresent disclosure provide a fastener comprising: a shank having a firstend and a second end opposite the first end, the second end including atip, the shank having a first longitudinal axis extending from the firstend to the second end; at least one helical thread formation integrallyconnected to and extending outwardly from the shaft; and a headintegrally connected to the first end of the shaft, the head including atop portion and a bottom portion, the top portion defining an engagingstructure engageable by a tool, the head having a second longitudinalaxis, the bottom portion including a plurality of ribs extendingradially around the second longitudinal axis of the head and extendingtoward the second end of the shaft, wherein each rib includes: (i) aleading face, and (ii) a trailing face that meets the leading face at atransversely extending leading edge of the rib, the leading edge of therib including an apex at the outermost end point of the leading edge,and wherein each rib is inwardly tapered from an outer surface of thehead toward the second longitudinal axis.

In various such embodiments of the fastener, the bottom surface of thehead is formed by the ribs.

In various such embodiments of the fastener, the ribs are identicallysized and shaped.

In various such embodiments of the fastener, the ribs include: (a) afirst rib having a first leading face and a first trailing face thatmeet at a transversely extending first leading edge; (b) a second ribhaving a second leading face and a second trailing face that meet at atransversely extending second leading edge; (c) a third rib having athird leading face and a third trailing face that meet at a transverselyextending third leading edge; and (d) a fourth rib having a fourthleading face and a fourth trailing face that meet at a transverselyextending fourth leading edge.

In various such embodiments of the fastener, (a) the first leading edgeof the first rib includes a first apex at an outermost end point of thefirst leading edge; (b) wherein the second leading edge of the secondrib includes a second apex at an outermost end point of the secondleading edge; (c) wherein the third leading edge of the third ribincludes a third apex at an outermost end point of the third leadingedge; and (d) wherein the fourth leading edge of the fourth rib includesa fourth apex at an outermost end point of the fourth leading edge.

In various such embodiments of the fastener, the trailing face of eachrib extends toward and all the way to a leading face of an adjacent oneof the ribs.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including onlyfour, only five, or only six ribs extending radially around the secondlongitudinal axis of the head and extending toward the second end of theshaft, wherein each rib includes: (i) a leading face; and (ii) atrailing face that meets the leading face at a transversely extendingleading edge of the rib, the leading edge of the rib including an apexat the outermost end point of the leading edge, and wherein the trailingface of each rib extends toward and all the way to the leading face ofan adjacent one of the ribs.

In various such embodiments of the fastener, a bottom surface of thehead is formed by the ribs.

In various such embodiments of the fastener, the ribs are identicallysized and shaped.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including: (a) afirst rib having a first leading face and a first trailing face thatmeet at a transversely extending first leading edge; (b) a second ribhaving a second leading face and a second trailing face that meet at atransversely extending second leading edge; (c) a third rib having athird leading face and a third trailing face that meet at a transverselyextending third leading edge; and (d) a fourth rib having a fourthleading face and a fourth trailing face that meet at a transverselyextending fourth leading edge, wherein the leading edge of each ribincluding an apex at the outermost end point of the leading edge of thatrib, and wherein the trailing face of each rib extends toward and allthe way to the leading face of an adjacent one of the ribs.

In various such embodiments of the fastener, the ribs are identicallysized and shaped.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including: (a) afirst rib having a first leading face and a first trailing face thatmeet at a transversely extending first leading edge; (b) a second ribhaving a second leading face and a second trailing face that meet at atransversely extending second leading edge; (c) a third rib having athird leading face and a third trailing face that meet at a transverselyextending third leading edge; (d) a fourth rib having a fourth leadingface and a fourth trailing face that meet at a transversely extendingfourth leading edge; and (e) a fifth rib having a fifth leading face anda fifth trailing face that meet at a transversely extending fifthleading edge, wherein the leading edge of each rib including an apex atthe outermost end point of the leading edge of that rib, and wherein thetrailing face of each rib extends toward and all the way to the leadingface of an adjacent one of the ribs.

In various such embodiments of the fastener, the ribs are identicallysized and shaped.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including: (a) afirst rib having a first leading face and a first trailing face thatmeet at a transversely extending first leading edge; (b) a second ribhaving a second leading face and a second trailing face that meet at atransversely extending second leading edge; (c) a third rib having athird leading face and a third trailing face that meet at a transverselyextending third leading edge; (d) a fourth rib having a fourth leadingface and a fourth trailing face that meet at a transversely extendingfourth leading edge; (e) a fifth rib having a fifth leading face and afifth trailing face that meet at a transversely extending fifth leadingedge; and (f) a sixth rib having a sixth leading face and a sixthtrailing face that meet at a transversely extending sixth leading edge,wherein the leading edge of each rib including an apex at the outermostend point of the leading edge of that rib, and wherein the trailing faceof each rib extends toward and all the way to the leading face of anadjacent one of the ribs.

In various such embodiments of the fastener, the ribs are identicallysized and shaped.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including aplurality of multi-part ribs extending radially around the secondlongitudinal axis of the head and extending toward the second end of theshaft, wherein each multi-part rib includes: (i) a multi-part leadingface, and (ii) a multi-part trailing face that meets the multi-partleading face at a transversely extending multi-part leading edge of themulti-part rib, the multi-part leading edge of the multi-part ribincluding an apex at the outermost end point of the multi-part leadingedge, and wherein each multi-part rib is inwardly tapered from an outersurface of the head toward the second longitudinal axis.

In various such embodiments of the fastener, a bottom surface of thehead is formed by the multi-part ribs.

In various such embodiments of the fastener, the multi-part ribs areidentically sized and shaped.

In various such embodiments of the fastener, the multi-part ribsinclude: (a) a first multi-part rib having a first multi-part leadingface and a first multi-part trailing face that meet at a transverselyextending first multi-part leading edge; (b) a second multi-part ribhaving a second multi-part leading face and a second multi-part trailingface that meet at a transversely extending second multi-part leadingedge; (c) a third multi-part rib having a third multi-part leading faceand a third multi-part trailing face that meet at a transverselyextending third multi-part leading edge; and (d) a fourth multi-part ribhaving a fourth multi-part leading face and a fourth multi-part trailingface that meet at a transversely extending fourth multi-part leadingedge.

In various such embodiments of the fastener, (a) the first multi-partleading edge of the first multi-part rib includes a first apex at anoutermost end point of the first multi-part leading edge; (b) whereinthe second multi-part leading edge of the second multi-part rib includesa second apex at an outermost end point of the second multi-part leadingedge; (c) wherein the third multi-part leading edge of the thirdmulti-part rib includes a third apex at an outermost end point of thethird multi-part leading edge; and (d) wherein the fourth multi-partleading edge of the fourth multi-part rib includes a fourth apex at anoutermost end point of the fourth multi-part leading edge.

In various such embodiments of the fastener, the multi-part trailingface of each multi-part rib extends toward and all the way to amulti-part leading face of an adjacent one of the multi-part ribs.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including onlyfour, only five, or only six multi-part ribs extending radially aroundthe second longitudinal axis of the head and extending toward the secondend of the shaft, wherein each multi-part rib includes: (i) a multi-partleading face; and (ii) a multi-part trailing face that meets themulti-part leading face at a transversely extending multi-part leadingedge of the multi-part rib, the multi-part leading edge of the ribincluding an apex at the outermost end point of the multi-part leadingedge, and wherein the multi-part trailing face of each multi-part ribextends toward and all the way to the multi-part leading face of anadjacent one of the multi-part ribs.

In various such embodiments of the fastener, a bottom surface of thehead is formed by the multi-part ribs.

In various such embodiments of the fastener, the multi-part ribs areidentically sized and shaped.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including: (a) afirst multi-part rib having a first multi-part leading face and a firstmulti-part trailing face that meet at a transversely extending firstmulti-part leading edge; (b) a second multi-part rib having a secondmulti-part leading face and a second multi-part trailing face that meetat a transversely extending second multi-part leading edge; (c) a thirdmulti-part rib having a third multi-part leading face and a thirdmulti-part trailing face that meet at a transversely extending thirdmulti-part leading edge; and (d) a fourth multi-part rib having a fourthmulti-part leading face and a fourth multi-part trailing face that meetat a transversely extending fourth multi-part leading edge, wherein themulti-part leading edge of each multi-part rib including an apex at theoutermost end point of the multi-part leading edge of that multi-partrib, and wherein the multi-part trailing face of each multi-part ribextends toward and all the way to the multi-part leading face of anadjacent one of the multi-part ribs.

In various such embodiments of the fastener, the multi-part ribs areidentically sized and shaped.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including: (a) afirst multi-part rib having a first multi-part leading face and a firstmulti-part trailing face that meet at a transversely extending firstmulti-part leading edge; (b) a second multi-part rib having a secondmulti-part leading face and a second multi-part trailing face that meetat a transversely extending second multi-part leading edge; (c) a thirdmulti-part rib having a third multi-part leading face and a thirdmulti-part trailing face that meet at a transversely extending thirdmulti-part leading edge; (d) a fourth multi-part rib having a fourthmulti-part leading face and a fourth multi-part trailing face that meetat a transversely extending fourth leading edge; and (e) a fifthmulti-part rib having a fifth multi-part leading face and a fifthmulti-part trailing face that meet at a transversely extending fifthmulti-part leading edge, wherein the multi-part leading edge of eachmulti-part rib including an apex at the outermost end point of themulti-part leading edge of that multi-part rib, and wherein themulti-part trailing face of each multi-part rib extends toward and allthe way to the multi-part leading face of an adjacent one of themulti-part ribs.

In various such embodiments of the fastener, the multi-part ribs areidentically sized and shaped.

It should further be appreciated from the above, that variousembodiments of the present disclosure provide a fastener comprising: ashank having a first end and a second end opposite the first end, thesecond end including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shaft; and a head integrally connected to the first end of theshaft, the head including a top portion and a bottom portion, the topportion defining an engaging structure engageable by a tool, the headhaving a second longitudinal axis, the bottom portion including: (a) afirst multi-part rib having a first multi-part leading face and a firstmulti-part trailing face that meet at a transversely extending firstmulti-part leading edge; (b) a second multi-part rib having a secondmulti-part leading face and a second multi-part trailing face that meetat a transversely extending second multi-part leading edge; (c) a thirdmulti-part rib having a third multi-part leading face and a thirdmulti-part trailing face that meet at a transversely extending thirdmulti-part leading edge; (d) a fourth multi-part rib having a fourthmulti-part leading face and a fourth multi-part trailing face that meetat a transversely extending fourth multi-part leading edge; (e) a fifthmulti-part rib having a fifth multi-part leading face and a fifthmulti-part trailing face that meet at a transversely extending fifthmulti-part leading edge; and (f) a sixth multi-part rib having a sixthmulti-part leading face and a sixth multi-part trailing face that meetat a transversely extending sixth multi-part leading edge, wherein themulti-part leading edge of each rib including an apex at the outermostend point of the multi-part leading edge of that multi-part rib, andwherein the multi-part trailing face of each rib extends toward and allthe way to the multi-part leading face of an adjacent one of themulti-part ribs.

In various such embodiments of the fastener, the multi-part ribs areidentically sized and shaped.

It will be understood that modifications and variations may be effectedwithout departing from the scope of the novel concepts of the presentinvention, and it is understood that this application is to be limitedonly by the scope of the claims.

The invention is claimed as follows:
 1. A fastener comprising: a shankhaving a first end and a second end opposite the first end, the secondend including a tip, the shank having a first longitudinal axisextending from the first end to the second end; at least one helicalthread formation integrally connected to and extending outwardly fromthe shank, wherein the at least one helical thread formation isconfigured such that (a) when the fastener is rotated in a substrate ina first direction, the at least one helical thread formation causes thetightening of the fastener in the substrate, and (b) when the fasteneris rotated in the substrate in an opposite second direction, the atleast one helical thread formation causes the loosening of the fastenerin the substrate; and a head integrally connected to the first end ofthe shank, the head including a top portion and a bottom portion, thetop portion defining an engaging structure engageable by a tool, thebottom portion including a plurality of ribs, wherein each rib includes:(i) a leading face, and (ii) a trailing face that meets the leading faceat a transversely extending leading edge of the rib, wherein the leadingedge of the rib includes an apex at the outermost end point of theleading edge, and wherein for each rib, the rib is inwardly tapered, thetrailing face of the rib does not extend to a leading face of anadjacent one of the ribs, the leading face of the rib, the leading edgeof the rib, and the trailing face of the rib are configured such thatwhen the fastener is rotated in the substrate in the first direction,the leading edge of the rib is engageable with the substrate before thetrailing face of the rib.
 2. The fastener of claim 1, wherein each ribextends to the shank.
 3. The fastener of claim 1, wherein the ribs areidentically sized and shaped.
 4. The fastener of claim 1, wherein theribs only include: (a) a first rib having a first leading face and afirst trailing face that meet at a transversely extending first leadingedge; (b) a second rib having a second leading face and a secondtrailing face that meet at a transversely extending second leading edge;(c) a third rib having a third leading face and a third trailing facethat meet at a transversely extending third leading edge; and (d) afourth rib having a fourth leading face and a fourth trailing face thatmeet at a transversely extending fourth leading edge.
 5. The fastener ofclaim 4, wherein: (a) the first leading edge of the first rib includes afirst apex at an outermost end point of the first leading edge; (b)wherein the second leading edge of the second rib includes a second apexat an outermost end point of the second leading edge; (c) wherein thethird leading edge of the third rib includes a third apex at anoutermost end point of the third leading edge; and (d) wherein thefourth leading edge of the fourth rib includes a fourth apex at anoutermost end point of the fourth leading edge.
 6. The fastener of claim1, which only includes four ribs.
 7. The fastener of claim 1, which onlyincludes five ribs.
 8. The fastener of claim 1, which only includes sixribs.
 9. A fastener comprising: a shank having a first end and a secondend opposite the first end, the second end including a tip, the shankhaving a first longitudinal axis extending from the first end to thesecond end; at least one helical thread formation integrally connectedto and extending outwardly from the shank, wherein the at least onehelical thread formation is configured such that (a) when the fasteneris rotated in a substrate in a first direction, the at least one helicalthread formation causes the tightening of the fastener in the substrate,and (b) when the fastener is rotated in the substrate in an oppositesecond direction, the at least one helical thread formation causes theloosening of the fastener in the substrate; and a head integrallyconnected to the first end of the shank, the head including a topportion and a bottom portion, the top portion defining an engagingstructure engageable by a tool, the bottom portion including only four,only five, or only six ribs, wherein each rib includes: (i) a leadingface; and (ii) a trailing face that meets the leading face at atransversely extending leading edge of the rib, the leading edge of therib including an apex at the outermost end point of the leading edge,and wherein for each rib, the trailing face of the rib does not extendto a leading face of an adjacent one of the ribs, and the leading faceof the rib, the leading edge of the rib, and the trailing face of therib are configured such that when the fastener is rotated in thesubstrate in the first direction, the leading edge of the rib isengageable the substrate before the trailing face of the rib.
 10. Thefastener of claim 9, wherein each rib extends to the shank.
 11. Thefastener of claim 9, wherein the ribs are identically sized and shaped.12. A fastener comprising: a shank having a first end and a second endopposite the first end, the second end including a tip, the shank havinga first longitudinal axis extending from the first end to the secondend; at least one helical thread formation integrally connected to andextending outwardly from the shank, wherein the at least one helicalthread formation is configured such that (a) when the fastener isrotated in a substrate in a first direction, the at least one helicalthread formation causes the tightening of the fastener in the substrate,and (b) when the fastener is rotated in the substrate in an oppositesecond direction, the at least one helical thread formation causes theloosening of the fastener in the substrate; and a head integrallyconnected to the first end of the shank, the head including a topportion and a bottom portion, the top portion defining an engagingstructure engageable by a tool, the bottom portion including: (a) afirst rib having a first leading face and a first trailing face thatmeet at a transversely extending first leading edge; (b) a second ribhaving a second leading face and a second trailing face that meet at atransversely extending second leading edge; (c) a third rib having athird leading face and a third trailing face that meet at a transverselyextending third leading edge; and (d) a fourth rib having a fourthleading face and a fourth trailing face that meet at a transverselyextending fourth leading edge, wherein for each rib the trailing face ofthe rib does not extend to a leading face of an adjacent one of theribs, and wherein for each rib, the leading face of the rib, the leadingedge of the rib, and the trailing face of the rib are configured suchthat when the fastener is rotated in the substrate in the firstdirection, the leading edge of the rib will engage the substrate beforethe trailing face of the rib.
 13. The fastener of claim 12, wherein theribs are identically sized and shaped.
 14. The fastener of claim 12,wherein each rib extends to the shank.
 15. The fastener of claim 12,wherein the bottom portion of the head includes: (e) a fifth rib havinga fifth leading face and a fifth trailing face that meet at atransversely extending fifth leading edge.
 16. The fastener of claim 15,wherein the ribs are identically sized and shaped.
 17. The fastener ofclaim 15, wherein each rib extends to the shank.
 18. The fastener ofclaim 15, wherein the bottom portion of the head includes: (f) a sixthrib having a sixth leading face and a sixth trailing face that meet at atransversely extending sixth leading edge.
 19. The fastener of claim 18,wherein the ribs are identically sized and shaped.
 20. The fastener ofclaim 18, wherein each rib extends to the shank.